Apparatus for making patterned pile fabric



Nov. 17, 1964 M. M. BEASLEY 3,157,554

APPARATUS FOR MAKING PATTERNED PILE FABRIC Filed Oct. 10, 1960 2Sheets-Sheet 1 INVENTOR lllllllll'f'" Nov. 17, 1964 M, M. BEAsLL-:Y3,157,554

APPARATUS FOR 'MAKING PATTERNED PILE FABRIC Filed Oct. l0, 1960 2Sheets-Sheet 2 ATl'OgiEY United States Patent C) 3,157,554 APPARATUS FORMAKING PATTERNED PILE FABRIC Max M. Beasley, Chattanooga, Tenn.,assigner, by mesne assignments, to The Singer Company, New York, NX.,

a corporation of New Jersey Filed Get. 10, 1960, Ser. No. 61,766 4Claims. (Cl. 156-435) This invention relates to an apparatus for makingpatterned pile fabric, and more particularly for making a pile fabrichaving pile loops of selectively dilferent heights without employing themethods of weaving or tufting.

Although the art of making pile fabric by introducing loops of yarn orother fibrous material between transverse blades or slats and cementingthe loops together is known, this art has been practiced Very little andcertainly does not enjoy the wide recognition of .the weaving or tuftingindustries. It is believed that one reason this method of forming loopsbetween slats is not very popular is that machines and methodsheretofore conceived have only been capable of forming loop piles of auniform height, and consequently cannot complete with the variedpatterned fabrics of the weaving and tufting industry.

It is therefore an object of this invention to provide an apparatus forselectively varying the pile height in accord ance with a predeterminedpattern in a loop pile fabric produced without the use of looms ortufting needles.

Another object of this invention is to provide an apparatus forselectively forming loops of different heights between spaced transverseslats in which a separate individually controlled plunger is providedfor each yarn.

Another object of this invention is to provide an apparatus for makingan infinite variety of patterns by selectively forming high and lowloops between uniformly spaced transverse slats.

Another object of this invention is to provide a novel method of makingpatterned loop pile fabrics with a minimum of material and equipment andmore economically than can be produced by weaving or tufting.

Further objects and advantages of this invention will be apparent from`the following description, taken in conjunction with the drawings,wherein:-

FIG. l is a sectional elevation of the apparatus made in Aaccordancewith this invention;

FIG. 2 is an enlarged sectional elevation of the loop forming member inraised position preparatory to forming a high loop;

FIG. 3 is a view similar to FIG. 2, but with the loop forming member inits lowermost position to form a high loop;

FIG. 4 is a View similar to FIG. 2 with the loop forming member inraised position preparatory to forming a low loop; and

FIG. 5 is a view similar to FIG. 4 with the loop forming member in itslowermost position to form a low loop.

Referring now to the drawings in more detail and par ticularly to FIG.l, the apparatus comprises a main frame or housing upon which isjournaled a horizontally disposed rotary shaft 11 supporting a drum orroll 12. Spaced to the rear of the housing 16 is another similar shaft13 supporting a roll 14. Adapted to engage the peripheries of both rolls12 'and 14 for rotary movement therewith is an endless belt or belts 15.Mounted transversely of the frame 10 on the outside of the endless belt15 is a plurality of uniformly spaced straight transverse slats or bars16 of uniform size. These slats 16 may be formed integrally with thebelt 15 and made of a hard plastic material, such -as rubber, or anyother convenient material which will cause them to iex as the belt l5travels around the peripheries of the rolls 12 and 14. To

ice

assist in supporting the upper'leg of the belt 15 as it travels beneaththe operating elements of the apparatus, is a platform 17. ln order tomove the belt 15 in the direction of the arrow, the shaft ll may bedriven by any convenient means, such as a motor, not shown. The shaft 13may be journaled for rotary movement in any convenient means, not shown.

Mounted on the upper part of the main frame or housing 10 is the maindrive shaft 20 to which is iXed one or more eccentrics 21, each of whichis linked by a connecting rod 22 to a push rod 23 in such a manner thatrotation of the main drive shaft 20 will cause the push rod 23 toreciprocate at a uniform stroke. The push rod 23 is supported forvertical reciprocation by the push rod housing 24. Mounted on the lowerend of the push rod 23 is the loop forming member 25 comprising acarrier including an upper carrier plate 26 supporting a transversecarrier bar 27.

The carrier bar 27 includes a plurality of uniformly spaced verticalguideways 28 in transverse alignment, only one of which is shown.Slidably mounted in each guideway is a plunger 29 having a flat lowerend or blade 30 of a thickness adapted to penetrate between any pair ofadjacent slats 16 in the path of the reciprocable blade andsimultaneously to carry a portion of yarn 32 snugly between the slats.In order to hold each plunger 29 Within its guideway 28 and to permitlimited reciprocation of the plunger 29 relative to the guideway 2S, akeyway or flat 34 is formed in one side of the plunger 29. A stationarykey or dog 35 extends from the guideway wall into `the keyway 34. Thedifference between the depth ofthe keyway 34 and the key 35 is equal tothe difference in the depth of penetration of the loop forming blade 30between the adjacent slats 16.

In order to lock the plunger 29 in its extended position for deepestpenetration, a hole 36 is formed in the front of the carrier bar 27 tointersect the plunger guideway 28. Adapted to reciprocate from front torear within the hole 36 s a latch pin 37. It can be seen from FIGS. 2-and 3 that when the latch pin 37 has been moved to the left into theguideway 28 and above the plunger 29, the plunger 29 will be locked inits extended position between the latch pin 37 and the key 35. Thus,when the push rod 23 is reciprocated to its lowermost position, the loopforming blade 30 will penetrate to its greatest depth and form a highloop 40 between an adjacent pair of slats 16, as best disclosed in FIGS.2 and 3.

When the latch pin 37 is withdrawn toward the front of the machine or tothe right in FIGS. 4 and 5, the plunger 29 is free to reciprocate withinits guideway 28 to the limits permitted by the engagement of the key 35within the keyway 34. Thus in FIG. 4, when the 'push rod 23 is movingupwardly, the plunger 29 will assume its lowermost position because ofgravity and inertia. On the other hand, when the push rod 23 isdescending at a rather rapid rate, the inertia of the plunger 29 plusthe pressure of the yarn 32 against the tip of the blade 30 will causethe plunger 29 to move to its uppermost position within the guideway 28,as best disclosed in FIG. 5. In such a position, the blade 30 will forma low or short loop 41.

In order to control the movements of the latch pin 37, it is linked bymeans of a connecting rod 44 to the armature 45 of a solenoid 46. Eachsolenoid 46 is controlled by an electrical lead 47 which terminates in aswitch 48. The switch 48 is opened and closed by means of a pivotedfinger 49 which is adapted to be pvoted by means of engagement ordisengagement with grooves 50 in a pattern sheet 5l mounted on a patterndrum 52 which is continuously and synchronously rotated on shaft 53 bymeans such as a motor, not shown. l

In order to prevent yarn 32 from being robbed from previously formedloops by the peneration of the loop pile fabric.

forming blade 30 between slatsV 16, a presser foot 55V is providedincluding a platel 56 for Vengaging thebase portions `ofthe previouslyformed loops 40, 41. The plate 56is supported at` the lower end of avertical rod 57 adapted to freely reciprocate in an opening in thecarrier plate 26. A coil spring VS8 is disposed between vthe carrierplate Zo and the presser foot plate Soin order to urge the presser plate56 Vaway from the carrier and down into holding engagement against thebase portions of the Aloops 40 and 41. Downward movement of the presserfoot 55 relativeto 'the loop forming member 25 is limited by the ange 59on top of the rod 57. Thus, it can be seenvfrom Vthe sequence ofoperations disclosed in FIGS..2 and 3 or FIGS. 4 and 5, the presser footplate 56 will be suspended above the loops When'the loop forming memberis in its uppermost position, but ask the member 25descends, thepresserfoot platef willenga'ge the baseportions of theloops 40 and'41 andthe Ypressure between the plate S6 and the loops will gradually increase tohold the loops in place as the blade descends with a loop portion ofyarn SZ'between slats 16. Uponascent of the loop forming member 25, thepressure between the presser foot plate 56 and thefloops completelydisengages the yarns in theV uppermost position of the loop formingmember 25 (FIGS. 2 and 4).

VIn order/to secure the loops 49, 41 in their pile-formed position, ahopper 6i? is located behind the loop forming member 25 for dispensing aplastic adhesive material 61,V such as polyvinyl chloride paste, whichis slowly metered out upon the upper base portions of the loops 49 and41. A spreader orl doctor blade 62 may also be mounted behind the hoppert'to'level, the material 61y to a uniform backing.- An infra red'heater6,3 is located behind the'spreader 62` in order to dry the plasticYmaterial 61 and cause it to set to form a backing material VKfortheAfter the plastic coating 61 has set,V the slats 16 separate by virtueof their travel around Vthe peripheryy of the drun'i14 in order torelease the loops 40 and 4l. The completed fabric may thenbe con- Vveyedto a subsequentrstation to be rolled for storage or apparent. v The drumshaft 11, the main drive shaft 20,V

the pattern drum shaft 53 and the Vyarn feed rolls 65 and 66 may all berotatedl synchronously from'arcommon power source, such as a motor, notshown. As the belt '15 and the slats 16 move toward the rear of themachine,

yarn 32 is fed in the same direction acrosstheV slats and in the path ofthe reciprocating plunger blade 30.- Assum- V ing that the pivotediinger'49V engages momentarily the surface-of the pattern sheet 51 toopen the switch '48,

' the'solenoids 46 will remain inactivated soth'at'the latch pin V3 7remains 4in its extended locking position'in the guideway 2S to maintainthe plunger 29 inV its extended 1 positionY fordeepest penetrationbetween the slats 16. Rotation of the main drive shaft 2li willtherefore cause the loop forming'member ZS'tojmove from its upperposition disclosed in FIG. 2 to its'lowermost position disclosedlin FIG.3Q whereby 'the ,presserV foot 55 will firmlyV gripV the. baseV portionsof the previously formed .loops "and the v plunger blade V36 willdescend to its lowermost position between the adjacent slats 16 to formaY high loopy dil. The loop forming VelementZS reciprocates upward'toagain assume its position in FIG. 2, and

f 1Assurningrithat theV pivo'ted pattern'inger 49 falls into Y agrooveofapattern sheet 51 to close the switch V4S andthereby'actuatel thesolenoid'fioto withdraw the latch i Y pin 37fto the positionv disclosedin FIG. 4, downwardY re-VY V4d, 41V will gradually decrease until thepresser Vfoot 55 f 1 the belt 15 continues to move toward the left sothat the j V-vnext/successive pair ofadjacent slats16 willalignthemselves in the path of the plunger blade Sill.

Y the'diference 4 Y ciprocation of the loop'forming element 25 Awillcause the plunger 29 to move from its position disclosed in FIG, 4 toits raised or withdrawn position disclosed in FIG. 5 and thereby form ashort loop 41. The presser foot 55 operates in the sameY mannerregardless of the relative position of the plunger 29 with respect Vtothe ,loop forming element 25.

Both high loops 4i) and low loops 41 are held Vbetween the slats 16 asthey pass beneath the hopper 6tlptheY doctor blade 62 and the infra reddryer 63; By the time the loops have reached the rear end of theyplatform 17, the plastic coating 61 has set to form a backing materialfor the fabric and the loops are released by the separation of the slats16 rotating around the drum 14.

Y. It will be understood that, even though only asideY elevation" of oneplunger 29, yarn 32 and solenoid'46 have been disclosed, this machine isparticularly adapted for a plurality of similarunitsdisposedtransverselyrof the machine so that each yarnV 32 i's individuallyVcontrolled to form a high loop or a low loop at any point in the fabricto create an innite variety of patternsfof high loops and low loops in apile fabric made in accord;- ance with this invention. It is alsopossible. under this invention to provide aV plunger bladev 39 whosetransverse v width is equal Vto the gauge of the fabric or toV amultiple of the gauge. vFor example, a plunger blade 30 could have awidth sufcient to control two, three or four adjacent yarns. Y

lt will be apparent to those skilled in the art that varv ious changesmay be made in the invention, without departing from the spirit andvscope thereofi and therefore the vinvention. is not limited to thatwhich is shown lin the drawings and described in the specifications, butonly as indicated in the appended claims. Y Y

Nhatis claimed is: Y l f 1. Anapparatus for making .patterned Ypilefabric comprising a plurality of uniformly andlongi'tudinally spacedtransverse slats, means,A for moving said slats in one longitudinaldirection, meansfor Vfeeding a yarn across said slats in said onedirection, apile forming carrier, means for continuously reciprocatingsaid carrier in a direction normal to'the plane of movement of said Ysaid plunger in said carrier to reciprocaterelative to saidYV carrier insaid normal direction, first means for positioning said plunger in saidcarrier to carry aportion of said yarn to a first deep position betweena pair of adjacent slats to form a high loop'when saidcarrier isinoperative postion; second means for positioning said plunger in saidcarrierfto carry a portion of said yarn Vto a secondV Vshallowpositionbetween a pair of adjacent slats to"fo`rm a low loop when saidcarrier is in operative position,

and means for coating the yarn portions connecting saidV Y loops to forma backing for said pile'fabric.

2. The invention according to claim 1 in. whichrsaid iirstpositioningrvmeans comprises latch means reciprocably mounted in saidcarrier, Vand means forrecipf.v rocating said latch means selectively tolatch said plungerV v in said firstV position Vand to unlatch saidplunger.

v 3; The invention according" to claimfl in which said secondpositioning means comprises a keyway formed on i one side of saidplunger and a key in said'carrier extending into said keyway, thedimension Vof said keyway'par- Y allel to saidnormal directionbeinggreater'thanthe cor.-

responding dimension of said key by afjdistance equal toY in depthbetween saidjfirstv and vsecond posi.

Y 4. An 'apparatus for making'patternedpile Vfalririccorn,`V prising aplurality of uniformly andlongitudinally spacedV transverse slats,"meansYfor moving said slats in one lon? Y Vgitudinal direction,means,forVfeeding a yarn'across fsaiclY slats inKsaid one direction, a pileforming carrier,fnnzansV for continuously receprocating said carrier ina direction normal to the plane of movement of said slats between anoperative position adjacent said slats and an inoperative posit-ionremote from said slats, a guideway in said carrier having an axisparallel to said normal direction, a plunger adapted to carry a portionof said yarn snugly between a pair of adjacent slats, said plunger beingreceived in said guideway for reciprocable axial movement therein, alatch pin, means in said carrier for slidably receiving said latch pinfor selectively latching said plunger in said carrier to carry a portionof said yarn to a irst deep position between a pair of adjacent slats toform a high loop when said carrier is in operative position and forunlatching said plunger, a keyway formed on one side of said plunger anda key in said carrier extending into said keyway, the axial dimension ofsaid keyway being greater than the axial dimension of said key by adistance equal to the difference in the depth between said first deepposition and a second shallow position of said plunger, said key beingadapted to engage one end of said keyway to maintain said plunger insaid shallow position when said plunger is unlatched and when saidcarrier is in operative position, and means for coating the yarnportions conneeting said loops to form a backing for said pile fabric.

References Cited by the Examiner UNITED STATES PATENTS 1,984,330 12/34Boyce 112-221 2,116,048 5/38 Smith 154-78 EARL M. BERGERT, PrimaryExaminer.

4. AN APPARATUS FOR MAKING PATTERNED PILE FAVRIC OCMPRISING A PLURALITYOF UNIFORMLY AND LONGITUDINALLY SPACED TRANSVERSE SLATS, MEANS FORMOVING SAID SLATS IN ONE LONGITUDINAL DIRECTION, MEANS FOR FEEDING AYARN ACROSS SAID SLATS IN SAID ONE DIRECTION, A PILE FORMING CARRIER,MEANS FOR CONTINUOUSLY RECEPROCATING SAID CARRIER IN A DIRECTION NORMALTO THE PLANT OF MOVEMENT OF SAID SLATS BETWEEN AN OPERATIVE POSITIONADJACENT SAID SLATW AND AN INOPERATIVE POSITION REMOTE FROM SAID SLATS,A GUIDEWAY IN SAID CARRIER HAVING AN AXIS PARALLEL TO SAID NRMALDIRECTION, A PLUNGER ADAPTED TO CARRY A PORTION OF SAID YARN SNUGLYBETWEEN A PAIR OF ADJACENT SLATS, SAID PLUNGER BEING RECEIVED IN SAIDGUIDEWAY FOR RECIPROCABLE AXIAL MOVEMENT THEREIN, A LATCH PIN, MEANS INSAID CARRIER FOR SLIDABLY RECEIVING SAID LATCH PIN FOR SELECTIVELYLATCHING SAID PLUNGER IN SAID CARRIER TO CARRY A PORTION OF SAID YARN TOA FIRST DEEP POSITION BETWEEN A PAIR OF ADJACENT SLATS TO FORM A HIGHLOOP WHEN SAID CARRIER IS IN OPERATIVE POSITION AND FOR UNLATCHING SAIDPLUNGER, A KEYWAY FORMED ON ONE SIDE OF SAID PLUNGER AND A KEY IN SAIDCARRIER EXTENDING INTO SAID KEYWAY, THE AXIAL DIMENSION OF SID KEYWAYBEING GREATER THAN THE AXIAL DIMENSION OF SAID KEY BY A DISTANCE EQUALTO THE DIFFERENCE IN THE DEPTH BETWEEN SAID FIRST DEEP POSITION AND ASECOND SHALLOW POSITION OF SAID PLUNGER, SAID KEY BEING ADAPTED TOENGAGE ONE END OF SAID KEYWAY TO MAINTAIN SAID PLUNGER IN SAID SHALLOWPOSITION WHEN SAID PLUNGER IS UNLATCHED AND WHEN SAID CARRIER IN INOPERATIVE POSITION, AND MEANS FOR COATING THE YARN PORTIONS CONNECTINGSAID LOOPS TO FORM A BACKING FOR SAID PILE FABRIC.